Device for angularly coupling prosthetic components

ABSTRACT

An angularly adjustable coupler is provided having first and second ends that are in an angularly adjustable mating engagement. The first end has a longitudinal axis and a base with an optionally concave and serrated surface, and can comprise a collared clamp for connecting to a pylon. The second end has a longitudinal axis and a base with an optionally convex and serrated surface, and can comprise a receiver for connecting to a pyramidal adapter. The concave portion of the first end and the convex portion of the second end are complementary to each other. A connector is provided to connect the first and second ends in a selected angular alignment about a fixed axis of rotation. The range of angular alignment of the first and second components spans approximately 50 degrees about the fixed axis of rotation.

This application is a divisional application of U.S. patent applicationhaving Ser. No. 10/626,134 filed Jul. 25, 2003 now U.S. Pat. No.7,097,666, the contents of which are hereby incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a device used to couple prostheticcomponents, and more particularly to adjustably couple prostheticcomponents in a selected angular relationship.

2. Description of the Related Art

Sometimes, due to accidents, health problems, birth defects, etc.,people 5 need to have a limb 6 amputated. The amputated limb 6terminates in a stump 7. In general, a socket 10 can be formed for aparticular stump 7. Those sockets 10 are well known in the art, and eachsocket 10 has a central axis 11.

Fortunately for people requiring a prosthetic limb, much advancement hasbeen made in the field of prosthetic limbs. Patients now have manychoices, including endoskeletal and exoskeletal prosthetic limbs. Thepresent invention relates to endoskeletal prosthetic limbs. That is,limbs comprised of structural components and an optional aesthetic outershell.

Many prosthetic components are available for use in endoskeletalprosthetic limbs. One of the most common types of prosthetic componentsis a pylon, which can comprise an aluminum or titanium alloy tube ofpredetermined length. A clamp can be used to connect to a pylon. Someconnectors have two opposed clamps for coupling two pylons. These typesof connectors are effective at coupling pylons in a fixed manner. Forexample, some connectors of this type couple two pylons in a linearmanner, where the two pylons are parallel to each other. Otherconnectors of this type are angled. For example, Otto Bock manufacturesa part, having part number 4R56, that provides a fixed and angledconnector for two pylons. There is no internal adjustability provided bythese types of connectors. Hence, these connectors are incapable ofmaking angular adjustments between two prosthetic components beingcoupled without additional components.

Another type of existing prosthetic component is a pyramidal adapter,which is adapted to be received within a receiver that has four screwsthat clamp onto the sides of the pyramid. Using a pyramidal adapter incombination with a receiver is useful in making angular adjustments inboth the lateral-medial directions, 15 and 16 respectively, andanterior-posterior directions, 17 and 18 respectively. Yet, thecombination of the pyramidal adapter and receiver is only useful formaking angular adjustments within a limited range. This limitation isdemonstrated in FIG. 1, where the socket 10 has an end 12 that is notperpendicular to the socket central axis 11. Thus, a three prong adapter20 that is connected to the end 12 of the socket has a central axis 21that is not parallel with the socket central axis 11. Rather, the threeprong adapter central axis 21 is offset from the socket central axis 11by an angle α. Angle α can have both a lateral-medial component and ananterior-posterior component. Further, the angle α is greater than theangular adjustability possible by using a pyramidal adapter 30 andreceiver 45 combination, which is shown as angle β. It is demonstratedthat because angle α is greater that the maximum angular adjustabilitybetween the pyramidal adapter 30 and fixed receiver 45, angle β, thepylon longitudinal axis 46 is not parallel to the socket central axis11. This may seriously interfere with a person's ability to walk. Thus,existing pyramidal adapters 30 and receiver 45 combinations may fail tomeet the needs of some people.

This type of pyramidal adapter and receiver combination is furtherillustrated in U.S. Pat. No. 3,659,294. This patent shows an adjustablelink for a prosthetic limb. Two parts are shown. One part has afrustopyramidal male end. The second part is a female socket. The socketconnects to the frustopyramidal male end in an angular configuration.The link shown in this patent may work well for its intended purpose.However, as discussed above, there is a limit to the adjustability ofthe link, which can be smaller than necessary depending on a particularpatient's needs. Also, the device shown in this patent has no presetadjustments. Further, the device shown in this patent is not adjustableabout a fixed axis of rotation.

U.S. Pat. No. 5,888,232 to Taylor discloses an adjusting connectorhaving a pylon or an adapter with a convexly hemispherical protrudingportion. A female contact surface with a concavely hemispherical seat isnecessary for use with the convexly hemispherical protruding portion ofthe adapter and pylon. These components are not interchangeable withexisting prosthetic components. Further, these components do not rotateabout a fixed axis of rotation.

Thus, there exists a need for an angularly variable coupler that solvesthese and other problems.

SUMMARY OF THE INVENTION

The present invention relates to an angularly adjustable coupler for usewith existing prosthetic components, and more particularly to anangularly adjustable coupler having a first end adapted to connect to afirst prosthetic component and a second end adapted to connect to asecond prosthetic component. The first end and second end are in anangularly adjustable mating engagement.

The first end has a longitudinal axis and has a prosthetic connector,such as a collared clamp, for connecting to a first prostheticcomponent, such as a pylon. The first end also has a base with a surfacethat is preferably concave and serrated.

The second end has a longitudinal axis and has a prosthetic connector,such as a receiver, for connecting to a second prosthetic component,such as a pyramidal adapter. The second end also has a base with asurface that is preferably convex and serrated.

The concave portion of the first end and the convex portion of thesecond end are complementary to each other. A connector is provided toconnect the first end to the second end. The connector can be comprisedof a pin that extends through a hole in the base of the second end, anda fastener extending through the first end base, partly through thesecond end base and into the pin, to hold the concave portion of thefirst end against the convex portion of the second end in a selectedangular alignment. That is, the first end longitudinal axis is in anadjustably selected angular alignment with the second end longitudinalaxis about the fixed axis of rotation. The range of angular alignment ofthe first end with respect to the second end about a fixed axis ofrotation is approximately 50 degrees.

The present invention is interchangeably usable with existing prostheticcomponents. Therefore, the prosthesis professional is not limited tousing specialty components in order to obtain the benefits of thepresent invention.

The present invention has a larger range of angular adjustability thanan existing pyramidal adapter and receiver combination about a givenaxis of rotation. This allows the present invention to be used insituations where the maximum angular adjustability range provided by apyramidal adapter and receiver combination is insufficient.

In accordance with another aspect of the present invention, the coupleris internally adjustable about a fixed axis or rotation. In oneembodiment of the present invention, the coupler can be incrementallyadjusted about the fixed axis of rotation, yet rigid when the connectoris tightened. In that embodiment of the present invention, eachsuccessive serration is offset approximately 2.5 degrees.

Other advantages, benefits, and features of the present invention willbecome apparent to those skilled in the art upon reading the detaileddescription of the invention and studying the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of background material showing thelongitudinal axis of a pylon being angularly offset from the centralaxis of a socket.

FIG. 2 is a first side view of the present invention.

FIG. 3 is a second side view of the present invention.

FIG. 4 is an exploded perspective view of the present invention.

FIG. 5 is a cross-sectional view of the first end of the presentinvention taken along line 5-5 in FIG. 4.

FIG. 6 is a cross-sectional view of the second end of the presentinvention taken along line 6-6 in FIG. 4.

FIG. 7 is similar to FIG. 2, but shows the first end in a first selectedangular alignment relative to the second end.

FIG. 8 is similar to FIG. 2, but shows the first end in a secondselected angular alignment relative to the second end.

FIG. 9 is an exploded view of the present invention showing a typicalset up comprising the present invention and other prosthetic components.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the invention will be described in connection with a preferredembodiment, it will be understood that it is not intended to limit theinvention to that embodiment. On the contrary, it is intended to coverall alternatives, modifications and equivalents as may be includedwithin the spirit and scope of the invention as defined by the appendedclaims.

The present invention relates to and comprises an angled coupler 50. Theangled coupler is preferably made of titanium alloy. However, otherstrong, yet light weight, materials can be used without departing fromthe broad aspects of the present invention. The angled coupler 50 ispreferably made in a computer numerical control (CNC) machining process.

Turning now to FIGS. 2 and 3, it is shown that the present invention hasa first end 60. The first end 60 has a first end longitudinal axis 61.The first end 60 also has a connector 65. One preferred connector 65 isa clamped collar, having a collar 66 and a clamp 67. A bolt 68 isprovided for inserting into the clamp 67. Turning the bolt 68 into theclamp 67 causes the perimeter of the collar 66 to shrink, and therebytightens the collar 66 around any item inserted into the first end 60.Other connectors can be used without departing from the broad aspects ofthe present invention.

The first end 60 of the angled coupler 50 also comprises a base 75. Thebase 75 has an interior surface 76 and an exterior surface 77, as shownin FIG. 5. The interior surface 76 is accessible through the connector65. The exterior surface 77 preferably has a concave portion 78. Theconcave portion 78 has serrations 79 in the preferred embodiment.Alternatively, the concave portion could be smooth (not shown) withoutdeparting from the broad aspects of the present invention. A screw hole81 is through the first end 60 in a direction generally parallel withthe longitudinal axis 61. The screw hole 81 is centrally located throughthe first end 60.

Turning again to FIGS. 2 and 3, it is shown that the angled coupler 50has a second end 90. The second end 90 has a longitudinal axis 91. Thesecond end 90 also has a connector 95. One preferred connector 95 is anadjustable clamp, comprising a receiver 96 having four holes 97therethrough. Screws 98 are provided for threadably turning into theholes 97 and into the receiver 96. The second end 90 can have adifferent type of connector without departing from the broad aspects ofthe present invention.

The second end 90 of the angled coupler 50 also comprises a base 105.The base has an interior surface 106 and an exterior surface 107, asshown in FIG. 6. The interior surface 106 is accessible through theconnector 95. The exterior surface 107 has a convex portion 108. Theconvex portion 108 has serrations 109 in the preferred embodiment.Alternatively, the convex portion could be smooth (not shown) withoutdeparting from the broad aspects of the present invention. A slot 111 isthrough the second end 90. The slot 111 generally lies in a planeparallel to the longitudinal axis 91 of the second end 90. A pin hole112 is also through the base 105. Pin hole 112 is generallyperpendicular to the longitudinal axis 91 of the second end 90, and alsoperpendicular to the plane containing slot 111.

Turning now to FIG. 4, a connector 120 is provided. The connector 120preferably comprises a rotatable pin 121 and a fastener 122. The pin 121has a longitudinal axis and a side. A hole is in the side in a directiongenerally perpendicular to the pin longitudinal axis. The hole in thepin 121 is preferably threaded. Two preferred fasteners 122 are screwsand bolts, having a head 123 and a shaft 124. The shaft 124 is threadedto threadably turn into the hole in the pin 121. Other types offasteners may be used without departing from the broad aspects of thepresent invention.

The first end 60 and second end 90 are adapted to be connected to eachother. In a preferred embodiment, the concave portion 78 of the firstend 60 mates with the convex portion 108 of the second end 90. Becauseof this mating engagement, the first end 60 can be connected to thesecond end 90 in a selected angular alignment about a fixed axis ofrotation 130. The connector 120 connects the first and second ends 60and 90. This is accomplished by inserting the rotatable pin 121 into thepin hole 112 through the second end 60 of the angular coupler 50. Thepin 121 is slightly smaller in diameter than the pin hole 112, such thatthe pin 121 can rotate freely within the pin hole 112. The fastener 122is inserted through the screw hole 81 through the first end 60 andthrough the slot 111 through the second end 90. The fastener 122 isthreaded into the rotatable pin 121 to securely hold the first end 60 inmating engagement with the second end 90. The head 123 of the fastener122 abuts the interior surface 76 of the first end 60.

As best shown in FIGS. 7 and 8, connector 120 can hold the first end 60in a selected angular alignment to angle φ with respect to the secondend 90 about a fixed axis of rotation 130. In the preferred embodiment,the pin 121, which is freely rotatable within the pin hole 112, is thefixed axis of rotation 130 about which the first end 60 can be rotatedrelative to the second end 90. In this regard, the first endlongitudinal axis 61 can be selectively angularly aligned with thesecond end longitudinal axis 91. In the preferred embodiment, the rangeof selectable angular alignment about the fixed axis of rotation 130 isapproximately 50 degrees. Serrations 79 and 109 are provided forincrementally adjusting the angular alignment of the first and secondends 60 and 90. Preferably, each successive serration 79 and 109provides for an incremental adjustment of approximately 2.5 degrees.

To adjust the angular alignment of the first end 60 with respect to thesecond end 90, the user first loosens the fastener 122 from the pin 121.The first end is the rotated relative to the second end about the fixedaxis of rotation 130 until the desired angular alignment is achieved.Then, the fastener 122 is tightened to the pin 121 to rigidly hold thefirst end 60 in the desired angular alignment with respect to the secondend 90, wherein the first end longitudinal axis 61 is offset from thesecond end longitudinal axis 91 by angle φ.

One advantage of the present invention can be seen upon comparison ofFIGS. 1 and 9. In FIG. 1, a three prong adapter 20 is aligned to beconnected to a socket 10. Because of the particular geometry of thesocket 10, and in particular the end 12 of the socket, the central axis21 of the three prong adapter 20 is angularly offset from the socketcentral axis 11 by an angle α. The pyramidal adapter 30 is connectableto the three prong adapter 20 in parallel alignment. The pyramidaladapter 30 is angularly connectable to the fixed receiver 45 of a pylon40. The maximum angular offset between the pylon 40 and pyramidaladapter 30 is angle β. As shown, angle α is greater than angle β. Thus,it is impossible to align the pylon longitudinal axis 46 parallel withthe socket central axis 11.

Turning now to FIG. 9, it is shown that the three prong adapter 20 isangularly offset from the socket 10, such that the three prong adaptercentral axis 21 is offset from the socket central axis by angle α. Theangled coupler 50 of the present invention is adjustable to an angle φ,which is approximately equal to angle α. In this regard, the angledcoupler 50 can be used to align the pylon longitudinal axis 46 parallelto the socket central axis 11, thereby fostering the person's ability towalk.

Looking more closely at FIG. 9, it is shown that the three prong adapter20 is attached to the socket 10 in a conventional manner. Depending onthe particular socket 10, the socket central axis 11 and the three prongadapter central axis 21 are offset by an angle α, which lies in a planedefined by the socket central axis 11 and the three prong adaptercentral axis 21. A pyramidal adapter 30 is then rotatably connected tothe three prong adapter 20. Because of this rotatable connection betweenthe pyramidal adapter 30 and three prong adapter 20, the pyramid of thepyramidal adapter 20 can be located in any desired rotationalorientation with respect to the three prong central axis 21. The pyramidhas four edges, which preferably generally form a square. In thepreferred rotational orientation of the pyramid, two of the edgesgenerally lie parallel to the plane defined by the socked central axis11 and the three prong adapter central axis 21 and two of the edgesgenerally lie perpendicular to said plane.

Then, the second end 90 of the angled coupler 50 is connected to thepyramidal adapter 30. Due to the rotatable orientation of the pyramidaladapter, the rotatable pin 121 is generally perpendicular to the planedefined by the socket central axis 11 and the three prong adaptercentral axis 21. Hence, the angled coupler has a fixed axis of rotation130 that is generally perpendicular to the plane defined by the sockedcentral axis 11 and the three prong adapter central axis 21, such thatthe first end 60 can rotate relative to the second end 90 in said planeto a selected angle φ, which is equal to angle α. Therefore, a pylon 40connected to the first end 60 of the angled coupler 50 will have alongitudinal axis 46 that is generally parallel to, albeit slightlyoffset from, the socket central axis 11.

It is noted that the angled coupler 50 can be adapted for use withdifferent prosthetic components without departing from the broad aspectsof the present invention. For example, a four prong adapter (not shown)could be used in place of the three prong adapter 20. Further, apyramidal adapter could be integral (not shown) with a three prongadapter rather than being a separate component.

The serrations 79 and 109 provide added structural rigidity to aprosthetic limb constructed with the present invention. However,sometimes, it is desirable to have greater angular flexibility. This canbe accomplished in at least two ways. First, the angled coupler 50 couldhave a first end with a smooth concave surface (not shown) and thesecond end with a smooth convex surface (not shown). In this regard, thefirst and second ends could be adjusted to an infinite number ofpositions about the fixed axis of rotation 130. Second, where apyramidal adapter 30 is used, the angled coupler 50 can provide themajority of the angular adjustment and the pyramidal adapter 30 can beused to make minor adjustments. In this regard, the pyramidal adaptercan be useful for making fine tune adjustments.

Thus it is apparent that there has been provided, in accordance with theinvention, a device for angularly coupling prosthetic components thatfully satisfies the objects, aims and advantages as set forth above.While the invention has been described in conjunction with specificembodiments thereof, it is evident that many alternatives,modifications, and variations will be apparent to those skilled in theart in light of the foregoing description. Accordingly, it is intendedto embrace all such alternatives, modifications, and variations as fallwithin the spirit and broad scope of the appended claims.

1. An angled coupler comprising: A. a fastener having a head and ashaft; B. a first end having: i. a first end longitudinal axis; ii. acollar with a clamp for receiving and securing an upper prostheticcomponent to said first end; and iii. a first end base connected to saidcollar, said first end base having a first end base interior surface anda first end base exterior surface, said first end base exterior surfacebeing concave and having serrations, said first end further having afirst end hole through said first end base in a direction generallyparallel to said first end longitudinal axis and being open to saidfirst end base interior surface, whereby said collar and said first endbase interior surface define a first end interior region wherein saidhead of said fastener engages said first end base interior surface andis accessible only through said first end interior region, and saidshaft passes through said first end hole and said first end baseexterior surface; C. a second end having: i. a second end longitudinalaxis; ii. a second end base with a second end base interior surface anda second base end exterior surface, said second end base exteriorsurface being convex and having serrations adapted to be matinglyconnected to said first end base exterior surface; iii. a slot extendingthrough said second end base in a plane generally parallel to saidsecond end longitudinal axis and longitudinally extending along saidconvex second base exterior surface and being open to said second endbase interior surface and said second end base exterior surface therebyallowing said shaft of said fastener to pass through said slot; iv. asecond end hole through said second end base in a direction generallyperpendicular to said second end longitudinal axis to create a singlepivot axis between said first end and said second end, and v. a receiverhaving set screws, said receiver connected to said second end base anddefining a cavity that opens in a direction opposed to said second endbase interior surface, said cavity selectably receiving said set screwsfor releasably retaining a lower prosthetic component; and D. a pinrotatably received in said second end hole being operable about saidsingle pivot axis and having a pin hole that is generally perpendicularto said single pivot axis, said shaft of wherein said fastener isinserted through said first end hole and said slot and into said pinhole in order to adjustably rotate said pin to move said shaft to adesired longitudinal position within said slot and matingly engage theserrations of said first end base and said second end base to rigidlyconnect said first end and said second end such that said first endlongitudinal axis is in a selected angular alignment with respect tosaid second end longitudinal axis and said first end is angularlyadjustable with respect to said second end about said single pivot axis.2. The angled coupler of claim 1 wherein said slot limits a range ofsaid selected angular alignment about said single pivot axis.
 3. Theangled coupler of claim 2 wherein said range of said selected angularalignment about said single pivot axis is approximately 50 degrees.